Operating Manual

Oil-cooled drum-type rheostatic

rotor starter
Type : DOA250/300A

Customer ...........................: F.E.P. International Traders, Inc.

Order-No ............................: 12041400321
Ident.-No.............................: 12000009015-16

Page 1 of 1

TECHNICAL DOCUMENTATION

Serial No.:
Type:

12000009015-16
DOA250/300A
CONTENTS / SUMMARY
1. IMPORTANT NOTE IN010
2. RECOMMENDATION FOR OIL
3. TECHNICAL SPECIFICATION
4. SERVICE / SAFETY INSTRUCTIONS L1.1 / FS / FSU
5. OUTLINE DRAWING MZ1630b
6. WIRING DIAGRAM / TERMINAL BLOCK SF1043c-1
7. DESCRIPTION OF WIRING DIAGRAM SF1043c-1
8. CIRCUIT DIAGRAM FOR CONTACT DRUM S1DAW947
9. STROKE ADJUSTMENT T30736a
10. COVER SHEET SPARE PARTS LIST
11. SPARE PARTS LIST
12. CHECKLIST 12000009015
13. CHECKLIST 12000009016

1/1

IN 010

ACHTUNG
Vor Anlegen der Prfspannung an den Widerstandsteil zwecks
Isolationsprfung mu der Mekreis mit den Klemmen n und o des
Frequenzrelais abgetrennt werden.

IMPORTANT NOTE
Before applying test voltage to the starting resistor for checking
insulation, make sure you have detached the measuring wires of the
frequency relay at terminals n and o.

ATTENTION
Avant dappliquer la tension dpreuve la rsistance de dmarrage fin
de vrifier lisolation, il faut dconnecter les cbles de mesure du relais
de frquence aux bornes n et o.

ATENCION
Antes de aplicar la tensin de ensayo a la resistencia de arranque pare
comprobar el aislamiento, es preciso desconectar los cables de
medicin del rel de frecuencia en los bornes n y o.

ATTENZIONE
Prima di applicare la tensione di prova sullelemento di resistenza per
controllarne lisolamento si deve staccare il circuito di misura con i
morsetti n ed o del rel di frequenza.

Page 1 of 1

RECOMMENDATION FOR OIL

Normal transformer oil according to VDE 0370/DIN 57370/IEC 296 is

applied, e.g. Shell Diala S2 ZU-I, Esso Univolt 56, BP Energol JS-HA.
Practical examinations have shown that it is not necessary to purify or
renew the oil filling even after a long working period as it is only
required to store heat energy and not to improve insulation.
The make or type of the transformer oil is not decisive, however in no
case may CLOPHEN, PYRANOLE or ASKAREL be filled in.

01/2012

Page 1 of 1

TECHNICAL SPECIFICATION
Oil-cooled drum-type rheostatic rotor starter
For three-phase slipring motor,
number of steps: 6
number of positions: 7,
balanced shorting,
starting time ta = appr. 20 s,
starting severity f = 1.4,
successive starts z = 3 from cold state,
periodic starts h = 1, number of starts per hour.
Required amount of oil approx. 100 l,
approx. weight 125 kg, (without oilfilling),
o-a-dim. acc. to MZ 1630b, size 2,
class of protection IP 54,
painting acc. to RAL 7035.
With servo-drive 3x440 V, 60 Hz,
incl. all necessary auxiliary switches,
emergency handwheel and
temperature switch F3/ F31,
control voltage 220 V, 60 Hz,
wiring according to SF 1043c-1.
For rated motor power 250 kW,
rotor 525 V, 289 A,
MK/MN = 2.2, nN = 900 rpm,
mass moment of inertia max. J = 120 kgm,
referred to rated motor speed,
for a BALL MILL drive.
Type: DOA250/300
Serial-No. 12000009015-16A
REMARKS:
- Temperature monitoring
- Oil level gauge
- Step interval monitoring
- Locked rotor control

Page 1 of 3

Service / Safety instructions L1.1 / FS / FSU

Safety instructions for the operation of starters
(In conformity with the low voltage directive 73/23/EEC)

1. General
In operation, starters, depending on their degree of protection, may have live, uninsulated and possibly also
moving or rotating parts, as well as hot surfaces.
In case of inadmissible removal of the required covers, of improper use, wrong installation or maloperation,
there is the danger of serious personal injury and damage to property.
All operations serving transport, installation and commissioning as well as maintenance are to be carried out by
skilled technical personnel (Observe IEC 364 or CENELEC HD 384 or DIN VDE 0105-100 and national
accident prevention rules!).
For the purposes of these basic safety instructions, "skilled technical personnel" means persons who are familiar
with the installation, mounting commissioning and operation of the product and have the qualifications needed
for the performance of their functions.

2. Intended use
Starters are components designed for inclusion in electrical installations or machinery.
In case of installation in machinery, commissioning of the starter (i.e. the starting of normal operation) is
prohibited until the machinery has been proved to conform to the provisions of the directive 98/37/EEC
(Machinery Safety Directive - MSD). Account is to be taken of EN 60204.
Commissioning (I.e. the starting of normal operation) is admissible only where conformity with the EMC
directive (89/336/EEC) has been established.
The starters meet the requirements of the low voltage directive 73/23/EEC. They are subject to the harmonised
Standards of the series prEN 50178/DIN VDE 0160 in conjunction with EN 60439-1/DIN VDE 0660, part 500.
The technical data as well as information concerning the supply conditions shall be taken from the rating plate
and from the documentation and shall be strictly observed.

3. Transport, storage
The instructions for transport, storage and proper use shall be complied with. The climatic conditions shall be in
conformity with prEN 50178.

4. Installation
The installation and cooling of the appliances shall be in accordance with the degree of protection. It is to take
into account a max. ambient temperature of 45C.
The starters shall be protected against excessive strains. In particular, no components must be bent or isolating
distances altered in the course of transportation or handling. No contact shall be made with electronic
components and contacts.
Starters contain electrostatic sensitive components which are liable to damage through improper use. Electric
components must not be mechanically damaged or destroyed (potential health risks).
Oil cooled starters must be filled with acidfree, mineral insulating oil of ambient temperature according to DIN
VDE 0370 corresponding IEC 296 (e.g. Shell Diala D, Esso UNIVOLT 52, BP T166 SGF, MOBILECT 37) up
to the middle of sight glass prior to commissioning.
Air cooled starters are equipped with a air inlet at the bottom and with a air outlet in class of protection IP23 at
the side. It is not allowed to cover this outlets. Distance to the walls > 0,5 m.

Page 2 of 3

5. Electrical connection
When working on live starters, the applicable national accident prevention rules (e.g. VBG 4) must be complied
with.
The electrical installation shall be carried out in accordance with the relevant requirements (e.g. cross sectional
areas of conductors, fusing, PE connection).
Observance of the limit values required by EMC law is the responsibility of the manufacturer of the installation
or machine.
Each unit is accompanied by a wiring diagram showing the electrical connections. Watch for good electrical
connections on terminals.
A correct polarity of the actuating motor is required to ensure proper function. In case the direction of rotation
compared with the wiring diagram and the description is not correct, the contact assembly should be brought to a
middle position. Polarity of the actuating motor must then be reversed by interchanging two phases (reverse
polarity of armature in case of DC or universal motors.)
If there are oil pumps, the sense of rotation is as well to check. For this the brass screwed cap on the motor
housing is to remove.
6. Operation
Installations which include starters shall be equipped with additional control and protective devices in
accordance with the relevant applicable safety requirements, e.g. Act respecting technical equipment, accident
prevention rules etc.
The technical data are found on the rating plate. During operation, all covers and doors shall be kept closed.
The starters are provided with notching facilities in each position and can be turned progressively from step to
step.
Only end limit positions of the starters are suitable for continuous operation. Keeping them in the intermediate
positions, even for temporary speed control, would case destruction of the unit.
Starters with remote drive are equipped with a pilot motor and a stepping mechanism. One complete revolution
will advance the switching gear properly by one step. As the catch roll engages the stepping wheel only during a
small angular movement, contact changing takes place rapidly. The individual contacts will always be fully
covered, because the stepping wheel acts also as a nothing wheel, and the actuating motor will be only cut off
whilst idling with stepping wheel out of mesh.
A switching procedure once initiated must not be interfered with by hand.
Controlling and locking as well as monitoring and protective functions (thermal motor protection, overcurrent
monitoring, thermostat, lock device etc.) may not be put out of operation, not even during trial service.
Systems may be mounted and operated only in the documented order.
7. Maintenance and servicing
Only carry out all work on the control devices, i.e. installation, connection, opening the device and maintenance,
when
- the system is free of electrical current,
- it cannot be switched on again and
- all drives are at a standstill
Before starting these works check the system to be without stresses using suitable tools.
The contact pressure and the connections should be checked regularly at larger intervals. Heavily worn contacts
must be replaced. Bearing and moving parts are to be greased sufficiently.
In case of oil cooled starters make sure, that oil is always free of physical pollution.
In case of air cooled starters the contacts must be maintained with an acid- and resinfree contact grease.
Should the catch roll be left engaged in the stepping wheel due to a supply failure, any attempt to proceed by
hand will prove impossible. In this case the motor shaft must be turned out of the mesh.

Page 3 of 3

8. Spare parts
When ordering spare parts, the 6 digit serial number of the equipment on the rating plate should always be
indicated to avoid incorrect supplies.

9. Warranty
Only in observance of and adherence to the respective valid operating instructions can the manufacturer's
warranty be upheld.

KEEP SAFETY INSTRUCTIONS IN A SAFE PLACE !

August 2002
lg.

DOA250/300A
12000009015-16

A
1 2.1A

21

K50
2.4D

22
21

S81
X2

Starter
ON/OFF

K0

1.2D

22

21

1
1

K0
2

1.2D

22

2
X2

13
2

13

S61

S64
14

21

11

F10

18

K1
1.3D

K2
22

1.3D

C
31

15

3.5D

12 14

14

21

1.5D

21X

K0

S69
15

22

1.2D

22X

13X

S80

K1
22

K3
32

2.4D

21

18

K50

1.3D

14X

43

Q10
2.8A
A1

A1

K0

K2
A2

44
A1

A1

K1

K3

A2

A1

Y1

K4

A2

A2

A2

Z2
2 2.1E

X2

Schritt - Zeitrelais
t i m e r f o r s t a r t i ngtime-adjustment

N
L1
(L+) ( L - )

1.3B 1
2.2B 5

1.4B 21
1.6C 21X

22
22X

3.4B 31X

32X

18

15

Sc ht z f r
Servo - Motor
c ont ac t or f or
p ilot -m ot or

2.8B 3

Stufenzeitberwachung
relay c om b. for
s t ep-int erv al-m onitor

1.6C 18

1.3C

1.4D 13X

14X

1.3C 21

22

15

18

15

3.5B

Zustand

nderung

Datum

Name

Datum
Bearb.
Gepr.
Norm

18.06.13
TB

U r s p r.

E r s.f.

E rs.d.

DOA250/300A

Fernantrieb
remote-drive

12000009015-16
5

=
+
Page 1
of 6

SF 1043c-1
6

8
L1 L2 L3 PE
X1

A
1
1

33 43

Q10

X3

S51

S50

Fernrckstellung
remote reset

K0
6

1.2D

22

22

1.3D
3

K7

-F31
>120C

1
X3

K8
2.3D

X3

PE

14

M1

11

Rastenhebelschalter
rachet switches
Handradschalter
i nt erloc k ing s w it c h
for handwheel
H ilf s w alz e - Sc halter
aux iliary cam switches

X2

X1
X2 X3

K7
no

1.8E

A1

A1

F5
A2

A1

H2

A2

A1
X2

K8
X2

A2

K50

16

A1

K130
A2

A1

K131
A2

A2

2
Frequency control

X3 5

max. 85C
warning

zum Anlasswiderstand
t o s t a r t i n g r e s is t or
Blockierschutz
l oc k ed rot or c ont rol
X3 4

2.2C 11

14

15

18

2.3C

2.3C 11
3.5D 21

PE

Servo-Motor
p ilot -m ot or

S80
12345 - - - - - - n

S60
S64
S301
S61
S35
S69
S302

15

0,15 KW
0,67A

S50

F5
14

M
3

S81

Sc hrit t ends chalter

s t e p l im it s w it c h

C
2.2D

3.5D

-F3
>85C

18

K1

11

15
2.2D

21

21

34 44
1.3D

1.8A

max. 120C
cut off

14
22

14

14

3.5D 11
1.3B 21

12
22

3.1B
12

11

12

11

1.5C 31

32

3.5C 21

22

3.5C 21

22

3.2B

S50 arbeit et nic ht

gleic hz eit ig m it S81
S50 do not work
simultaneously with S81

Zustand

nderung

Datum

Name

Datum
Bearb.
Gepr.
Norm

18.06.13
TB

U r s p r.

E r s.f.

E rs.d.

DOA250/300A

Fernantrieb
remote-drive

12000009015-16
5

=
+
Page 2
of 6

SF 1043c-1
6

X2

X2

X2
8

X2

17

1.2D
11

B
14

12

K130
2.4D

S35

14

18
12

12

K4

K131
11

2.5D

15

1.5D
11
X2

X2

20

18

Starter
in startposition
X2
7

12

32X

11

S302
12

S60

K0

19

Starter
in endposition

21

X2
10

11

S301

K131

12

22

2.5D
max. 85C
warning

23

11

31X
X2
5

X2

21

max. 120C
cut off

C
21

K130
2.4D

22

21

K8
2.3D 22
11

11

F10
1.1C

K50

14

2.4D

12

33

Q10
2.8A

34

X2

22

X2

Trip

24

Starter
ready for start

F
Datum

18.06.13
TB
Derpa

Bearb.
Gepr.
Zustand

nderung

Datum

Name

Urspr.

Norm

Ers. fr

DOA250/300A

Fernantrieb
remote-drive

12000009015-16
5

Page 3
of 6

SF 1043c-1

Ers. durch

=
+

Ziel intern
destination
internally

Anschlu
connection

1
3
5

Blatt/Pfad
page/path

2.8A
2.8A
2.8A
2.8A

Bezeichnung
designation

Q10
Q10
Q10

Seite
page
1

B
L1
L2
L3
PE

Brcken
links
Klemmennummer
terminal-no.

Ziel extern
destination
externally

Anschlu
connection

C
Bezeichnung
designation

Kabelbezeichnung extern
cable designation
externally

F
Datum

18.06.13
TB

Bearb.
Gepr.
Zustand

nderung

Datum

Name

Urspr.

Norm

Ers. fr

Ers. durch

DOA250/300A

Klemmenplan
terminal block
X1

12000009015-16
5

=
+
Page 4
of 6

SF 1043c-1
6

D
Kabelbezeichnung extern
cable designation
externally

Zustand
nderung

1
Anschlu
connection

Datum

Bezeichnung
designation

Datum

Bearb.

Name
Norm

2
X1
X2

Klemmennummer
terminal-no.
1
2
3
4
5
6
7
8
9
10
15
16
17
18
19
20
21
22
23
24

1
2

Anschlu
connection
E1
A1
E2
A2
12
14
11
12
14
11
14
A2
11
12
11
12
31X
34
11
12

Bezeichnung
designation
F10
K0
F10
K0
K130
K130
K130
K131
K131
K131
K8
K8
S35
S35
S302
S302
K0
Q10
S301
K50

ON/OFF
ON/OFF

Ziel intern
destination
internally

1.2B
1.2C
1.1E
1.1E
3.1B
3.1B
3.1C
3.2B
3.2B
3.2C
2.3D
2.3D
3.4B
3.4B
3.3B
3.3B
3.5A
3.5D
3.5A
3.5D

Blatt/Pfad
page/path

H2
H2

C
Ziel extern
destination
externally

Seite
page
2

1
2
3

18.06.13
TB
Urspr.

Ers. fr

12000009015-16

Gepr.

Ers. durch

Klemmenplan
terminal block
X2
6

Brcken
links
B

E
E

F
F

DOA250/300A
=
+

SF 1043c-1
Page 5
of 6

Ziel intern
destination
internally

Anschlu
connection

21
A1
A1
n
o

Blatt/Pfad
page/path

2.4B
2.4C
2.5C
2.2E
2.2E
2.5C

Bezeichnung
designation

S50
K130
K131
F5
F5

Seite
page
3

B
1
2
3
4
5
PE

Brcken
links

3
1
2

Klemmennummer
terminal-no.

C
Bezeichnung
designation

Kabelbezeichnung extern
cable designation
externally

-F3
-F3
-F31

Ziel extern
destination
externally

Anschlu
connection

F
Datum

18.06.13
TB

Bearb.
Gepr.
Zustand

nderung

Datum

Name

Urspr.

Norm

Ers. fr

Ers. durch

DOA250/300A

Klemmenplan
terminal block
X3

12000009015-16
5

=
+
Page 6
of 6

SF 1043c-1
6

Page 1 of 3

Description of Wiring Diagram

SF 1043c-1

The wiring diagram represents the internal wiring of the remote drive. The external
wiring may be derived from this diagram and can be changed to meet specific
safety and other measures the customers want to introduce.
The functioning of all equipment is checked by us. Proper operation of the drive can
however not be guaranteed unless the internal wiring remains unchanged and the
principle of the wiring is adhered too.
Watch for correct polarity of the pilot drive(s) when starting the drive.
The purposes of the various control members are as follows:

F3

temperature switch F3 is included in the stator circuitry. It operates at approx.

850C and prevents a further starting operation, which might initiate emergency
shut down via temperature switch F31.

F31

temperature switch F31 will deenergize the main drive in event of excessive
oil-temperature switch at approx. 1200C.

S301 an interlocking contact, that is closed only in the initial position of the control
gear thus permitting start of the motor only in this position, i.e. with total
starting resistor in circuit.
S302 works same as S301. It can be used for signalling purposes.
S35

is closed in the end position with the starting resistance completely shorted
out. It can be used for signalling, supervision etc. as desired.

Page 2 of 3
S50

is closed in each intermediate position and energizes then the relay K50.
Contact 11-12 of the relay K50 makes sure, that the mechanism has snapped
accurately into the position. It is linked in series with S301.
Contact 21-22 of the relay K50 opens the closing circuit of the contactor, so
that between the steps no new command will be effective. Mechanical damage
of the stepping mechanism, due by incorrect hand operation, is avoided by this
it prevents operation, if the drum controller is not properly adjusted to a full
step postion.
Contact 31-32 feeds pulses via relay K3 to relay K4. This circuit monitors the
performing of step charges.

S60

is closed within the whole operating range. Under emergency control by

handwheel the main line contactor will be tripped in case the initial or the limit
position are being exceeded due to maloperation. The latter is not possible
under automatic control.

S61

is a limit switch which opens the closing circuit of the control contactor prior to
reaching the limit position. Accurate stopping of the pilot drive by S81 will thus
be initiated.

S64

is open in the initial position. With the stator switch dropped out, it effects
travel beyond the limit position to the initial position, where the drive will be
stopped via step limit switch S81.

S69

bridges step interval monitoring after a starting procedure has been

completed.

S80

is interlocked with the clutch of the handwheel for emergency control. Upon
engaging the clutch for hand operation it opens the closing circuit of control
contactor. This prevents trouble by simultaneous hand- and remote-operation.

S81

is a step limit switch which opens the holding circuit of control contactor
momentarily after each completed step. It will, however, not become effective
unless the closing circuit of the control contactor has already been opened.
The drive will only be stopped accurately via S81 after a completed step, i.e.
in a proper drum position with pilot motor out of mesh.

Page 3 of 3

LOCKED ROTOR CONTROL

In order to protect the starting resistor against excessive currents which could
occur in event of the driven machine being blocked mechanically, a frequency
relay (F5) is installed.
F5 supervises rotor frequency which decreases as motor speed increases. If
rotor frequency does not decrease within a preset time lag (K7) to a stipulated
value, this will cause relay K8 to interrupt power flow by opening the external
mains contactor or circuit breaker. (Path Trip). Tripping will be indicated by
lamp H2 (extern).
Relay K8 remains engaged and thereby prevents switching on the mains
contactor KO until having pressed the reset button S51.
The metering input circuit of the frequency relay will bear up to 400 V. In case
of a higher rotor voltage at standstill, the starting resistor is tapped
accordingly.
Approximate dial settings:
F5 : 90 percent of full rated mains frequency
K7 : 20 percent of total starting time

DOA250/300A

Anlasser
Typ: O(A)'2$ Gre 0-4
Starter
Type: O(A)D2$ size 0-4
Dmarreur
Type: O(A)D2$ tailles 0-4
Arrancador
Tipo: O(A)D2$ tamaos 0-4

Segment: 12 Nm
Segment
Segment
Segmento

Anlasser Typ '2$ Gre 5-8

Drehzahlsteller ADK ... / DP ...
Starter type '2$ size 5-8
Speed regulator ADK ... / DP ...
Dmarreur type '2$ tailles 5-8
Graduateur de vitesse ADK ... / DP ...
Arrancador tipo '2$ tamaos 5-8
Regulador del nmero de revoluciones
ADK ... / DP ...

Segment: 9 Nm
Segment
Segment
Segmento

Fingerklotz: 17 Nm
Fingerhead
Patin du doigt
Cabeza del dego

5-6

Fingerklotz: 17 Nm
Fingerhead
Patin du doigt
Cabeza del dego

Zustand

Original neu
nderung

25.6.97
TB
Datum
Name

Datum
Bearb.
Gepr.
Norm

04.06.86
TB

12000009015-16
Urspr.

Ers.f.

Ers.d.

Ajuste de los dedos de contacto

Kontaktfingereinstellung
Stroke Adjustment
Ajustement des doigts de
contact
5
6

=
+
7

T 30 736a

Page 1
of

Seite/Page 1 von/of 4

ERSATZTEILE-LISTE
SPARE PARTS LIST

Gerte-Nr. / Serial No.:

12000009015-16

Typ / Type:

DOA250/300A

STEUERUNG / CONTROL UNIT

Gerte-Nr. / Serial No.: 12000009015-16
Pos.-Nr. Eingeb. Empf. Beschreibung / Typ
Stck Stck
Pos. No. Qty.
Qty. Description / Type
instal. recom.

Verstellmotor Gr. 1-4U

Pilot motor size 1-4U
Mitnehmer
Drive arm

Temperaturschalter
Temperature switch

7
1

1
2
1
2

Typ / Type : DOA250/300A

Material-Sach-Nr.
Material No.

BG06-31/DU04
(46,2UpM/rpm)

Seite/Page 2 von/of 4

PE 301 20 1931
P 090 017

(440V, 60Hz)

Lieferzeit
Preis
Bemerkungen
in Wochen EUR / Stck
Deliv. Time
Price
Remarks
weeks
EUR / piece
4W

M1

2W

(M1)

85C / 120C
2 no contacts

PE 301 30 164

3W

F3 / F31

Hilfsschalter
T 6881N
Auxiliary switch
Hilfsschalter
T 6881V
Auxiliary switch
Nockenscheibe, einzeln, gefrst
Cam disk (single, milled )

PE 301 00 011

1W

PE 301 00 012

1W

S81, S50, S60, S64/301

S61/35, S69, S302
S80

P 070 0012

1W

Taster
Pushbutton

PE 301 10 78

3W

S51

3W

K0, K1

3W

K1

3W

K0

E-215-16-11F

Steuerschtz
AF09-30-01-13 PE 301 10 0702110
Auxiliary contactor 100-250 V AC/DC
Hilfsschalterblock
CA4-10 PE 301 10 070311
Snap on switch
Hilfsschalterblock
CA4-01 PE 301 10 070322
Snap on switch
CT-ERS.12S
0,05s-300h; 1We, 1c/o
CT-WBS.22S
0,05s-300h; 2We, 2c/o
CT-AHS.22S
0,05s-300h; 2We, 2c/o

PE 301 10 07086

3W

K2, K7

PE 301 10 07104

3W

K3

Zeitrelais
Timing relay
Zeitrelais
Timing relay
Zeitrelais
Timing relay

PE 301 10 07096

3W

K4

Relais CR-M, kompl., 3 We, 230V AC

Relay CR-M, compl., 3c/o, 230 V AC

PE 301 10 07360

3W

K8, K50, K130, K131

Frequenzrelais
Frequency relay

PE 301 10 092

4W

F5

2
1

1
1
1
1

SL 9837
220 V

Motorschutzschalter
Manual motor starter
Hilfsschalter
Auxiliary contact

MS 116-1,0
0,63-1 A
HK1-20
2S; 2no

PE 301 10 0729

3W

Q10

PE 301 10 07231

3W

(Q10)

Sicherungsautomat
circuit breaker
Hilfsschalter
Auxiliary contact

S 201-C4
4A
S2C-H6R
1We; 1 c/o

PE 301 10 07901

3W

F10

PE 301 10 07904

3W

(F10)

SCHALTTEIL / DRUM CONTROLLER PART

Gerte-Nr. / Serial No.: 12000009015-16
Pos.-Nr. Eingeb. Empf. Beschreibung / Typ
Stck Stck
Pos. No. Qty. Qty. Description / Type
instal. recom.
Handrad Kunststoff, Gr. 1-4
Handwheel plastic, size 1-4
1

1
1

21
21

21

Seite/Page 3 von/of 4

Typ / Type : DOA250/300A

Material-Sach-Nr.
Material No.
PE 303 40 08

Lieferzeit
Preis
Bemerkungen
in Wochen EUR / Stck
Deliv. Time
Price
Remarks
weeks
EUR / piece
250 mm
1W
250 mm

Rastenhebel
Ratchet lever
Rastenfeder Gr. 3 - 4
Ratchet spring size 3 - 4

P 150 001

1W

PE 302 50 28

2W

Druckfeder fr Kontaktfinger
Pressure spring for contact finger

PE 302 50 21

1W

Kontaktfingerklotz
Contact finger head
Kontaktfingerklotz 1-8 vorne plattiert
Cont. finger head 1-8 front side tipped
Kontaktfingerklotz 1-8 hinten plattiert
Cont. finger head 1-8 back side tipped
Kontaktfingerklotz beidseitig plattiert
Contact finger head tipped both sides
Segment 1 - 4
Segment 1 - 4
Segment 1 - 4 vorne plattiert
Segment 1 - 4 tipped front side
Segment 1 - 4 beidseitig plattiert
Segment 1 - 4 tipped both sides

P 060 001

1W

P 060 0035

2W

P 060 0036

2W

P 060 004

2W

P 060 005

1W

P 060 007

2W

P 060 008

2W

Kontaktfinger 1 - 4
Contact finger 1 - 4
Kontaktfinger 1-4 vorne plattiert
Contact finger 1-4 front side tipped
Kontaktfinger 1-4 hinten plattiert
Contact finger 1-4 back side tipped
Doppel-Kontaktfinger 1 - 4
Twin contact finger 1 - 4
D.-Kontaktfinger 1-4 vorne plattiert
Twin contact finger 1-4 front side tipped
D.-Kontaktfinger 1-4 hinten plattiert
Twin contact finger 1-4 back side tipped

P 060 011

1W

P 060 0131

2W

P 060 0132

2W

P 060 017

1W

P 060 0191

2W

P 060 0192

2W

WIDERSTANDSTEIL / RESISTOR PART

Gerte-Nr. / Serial No.: 12000009015-16
Pos.-Nr. Eingeb. Empf. Beschreibung / Typ
Stck Stck
Pos. No. Qty.
Qty. Description / Type
instal. recom.
Widerstandselement E10
Resistor grid E10
3
Widerstandselement E14
Resistor grid E14
Widerstandselement E20
Resistor grid E20
3
Widerstandselement E28
Resistor grid E28
Widerstandselement E40
Resistor grid E40
6
Widerstandselement E55
Resistor grid E55
Widerstandselement E80
Resistor grid E80
Widerstandselement E55dv
Resistor grid E55dV
6
Widerstandselement E80dv
Resistor grid E80dV
6
Widerstandselement E110
Resistor grid E110
3
Widerstandselement E175
Resistor grid E175
Widerstandselement E230
Resistor grid E230
Widerstandselement E340
Resistor grid E340
Widerstandselement E470
Resistor grid E470
Widerstandselement E670
Resistor grid E670

Seite/Page 4 von/of 4

Typ / Type : DOA250/300A

Material-Sach-Nr.
Material No.
A 002 074

Lieferzeit
Preis
Bemerkungen
in Wochen EUR / Stck
Deliv. Time
Price
Remarks
weeks
EUR / piece
2W

A 002 075

2W

A 076 694

2W

A 002 077

2W

A 002 078

2W

A 002 079

2W

A 002 080

2W

A 001 778

2W

A 001 779

2W

A 076 695

2W

A 001 781

2W

A 001 782

2W

A 001 783

2W

A 001 784

2W

A 001 785

2W

Page 1 of 7

12000009015

HELMKE ORBIS GmbH

P.O. Box 1203, - 31152 Sarstedt/Germany
Tel. No. 05066/90333-0
FAX No. 05066/90333-145
E Mail: [email protected]
Internet: www.helmke.de

Check List

NOTE: The check list has to be filled in before commissioning and should then be
returned to: HELMKE ORBIS GmbH, Ludwig-Erhard-Ring 7-9, 31152 Sarstedt

Requirement: The starter may only be put into operation by qualified

personnel.

Remarks:
Prior to attaching rotor cables to terminals K, L, M and before having linked
the slipring (wound rotor) motor to the power supply functional off load
tests on the rotor starter may be performed without having filled transformer
oil into the starter tank in order to facilitate handling and inspection.
If thereby the starter has proved faultless transformer oil may be filled in
before connecting up rotor cables (for further details see item 3).

Page 2 of 7
Type of device:
Oil cooled drum type rheostatic rotor starter
assigned the designation
DOA250/300A
Serial No.:
12000009015
For starting a slipring motor,
motor power
rotor voltage at standstill:
rotor current at full rated speed
and at full load torque:

250 kW
525 V
289 A

Type of driven machine:

BALL MILL

Circuit diagram of pilot drive unit:

3phase power supply voltage:
1phase control voltage:
Outline drawing:
Degree of protection:

SF 1043c-1
440 V, 60 Hz
220 V, 60 Hz
MZ 1630b, size 2
IP 54

Will the run up procedure take place under the conditions and technical data for
which the starter has been calculated and designed?
(Please confirm)

yes

(Please confirm)

yes

Have steps been taken to prevent overload?

1.

Measuring Resistance Values

Prior to applying power to the stator side of the slipring motor and before
having attached rotor cable(s) to starter terminals K,L,M test the rotor starter:
1.1

Press down the handwheel and measure the ohmic values between
terminals K and L, K and M, L and M in each starter position.
(The handwheel can be fixed in the down position by use of a clip on the end of
shaft).

Page 3 of 7

Note down the values in the table below:

Position

K-L

K-M

L-M

In initial position the ohmic values between any two of the three rotor
terminals should be approx. 0.98 Ohms ( 10%).
The minimum ohmic value should read approx. zero Ohms and be in
final working position.
If the result is not satisfactory please contact HELMKE ORBIS immediately.
2.

Functional Test of the Pilot Drive Unit

2.1

Attach the control wires to the terminal strip of the pilot drive unit.
Apply power to the pilot drive unit only.
If the handwheel still is fixed in down position, release it.

Make sure the power supply to the stator side of the slipring motor continues
to remain interrupted, also in event of switching ON the slipring motor.
2.1.1 Does the starting resistance change from max. value 10% to approx.
zero within the run up time stated on the rating plate of the starter?
(Cross out what doesnt apply)

(If not, continue at item 5)

yes/no

Page 4 of 7
2.1.2 To check the step interval monitoring system keep the handwheel
pressed down for approx. 5 seconds at the beginning of a
simulated run up procedure.
After this time has run off, monitor system must trip.
After having released the handwheel the drum controller must
automatically return to first starting position with maximum resistance in
circuit.
Has the energy cut off signal been produced?

yes/no

(Cross out what doesnt apply)

(If the answer is no then continue at item 5)

Wiper relay K3 is and remains set to approx. 0.3 seconds on
principle. (For starters with step interval monitoring system only.)
2.1.3 In case of starters having a run up control system using rotor frequency
(locked rotor control) the corresponding relay settings must also be
checked.
A frequently adopted way of control setting will cut off energy if the
drive unit doesnt gain 10 percent of full speed beginning at standstill
within 20 percent of total run up time, i.e. timer K7 would be set to 20%
of run up time and frequency relay F5 would be set to 90% of mains
frequency.
Locked rotor control:
Frequency relay F5:
Timer K7:
Timer K7 - Range::
Timer K7 Setting:

54 Hz
4s
10 s
4

Are the settings unchanged?

Scale 15

Hyst 7.5%

(Please confirm)

yes

Page 5 of 7

3.

General Testing
Functional test temperature switch
F3 /F31 85 C/120C.
F4
./. C.
Have all earthing points been properly connected?

(Please confirm)

Have all mechanical and electrical safety regulations and

other laws that are in force at site been observed?

(Please confirm)

yes

yes

Has normal, acidless mineral transformer oil having ambient

temperature been used?

(With oil being at ambient temperature the oil tank may only be filled up
to the centre of the oil sight glass.)
(Please confirm)

yes

Has the oil filling been allowed to settle for about 2 or 3 hours?

yes

Have rotor cables been connected?

yes

(Please confirm)

Handwheel unlocked?

(Please confirm)

(Please confirm)

yes

Does power supply provide either full rated voltages or else voltages within
particularly acknowledged limits for operating the starter?
(Please confirm)
yes
In case of deviations beyond 5% of the specified range make sure to first
contact HELMKE ORBIS.

Page 6 of 7
4.

Measuring Insulation Resistance

Measuring insulation resistance between the 3 rotor terminals K,L,M and the
oil tank. The result should be approx. 10 megohms.
please enter the value: .......................megohms,
(measured with 500 V or 1000 V)
Final bench tests on starters in dry state yield values of approx. 80 to 100
megohms. With long storage periods and under the effect of moisture values
can drop to below 10 megohms. A field requirement would be to achieve at
least 1000 Ohm / V; (related to rotor Volts at standstill).

5.

Readjustments
If there has been a change in operating characteristics or mistuning which
necessitates readjustment proceed as below:
Change of run up time
A change of run up time will have to comply with instructions stipulated by
HELMKE ORBIS, achieved by adjustment of step intervals with relay K2.
This must always be verified by checking the complete run up time.
After having changed run up time it will also be necessary to reset the step
interval monitor!
Tuning the step interval monitor by resetting relay K4:
General rule:
Setting of K4 = maximum step interval + 1 to 2 seconds
(where 1 or 2 seconds is the tripping time)
For easy tuning of the step interval monitor the maximum period of time
between two consecutive pulses of K3 must be measured (LED lamps are on
the relay).
Time setting on relay K2 plus a time lag caused by the speed of the pilot
motor and tripping time 1 to 2 seconds add up to the required setting of K4.
The sensitivity of control settings on K4 necessitates practical testing. On
starters where the first step interval is longer than the following intervals
tuning only refers to the first step. This is achieved by pressing down the
handwheel before starting the pilot drive unit. Time then is measured from
start to trip.

Page 7 of 7

After having completed all changes run through the complete list once
more checking each detail!!
If serious deviations are found in any section of checking procedure the starter
may only be put to work on receipt of written approval by HELMKE ORBIS.
Company: .......................................................................................................
Place, date: .....................................................................................................
Signature: ........................................................................................................

Please return this check list to:

HELMKE ORBIS GmbH
Ludwig-Erhard-Ring 7-9
31152 Sarstedt
GERMANY

Page 1 of 7

12000009016

HELMKE ORBIS GmbH

P.O. Box 1203, - 31152 Sarstedt/Germany
Tel. No. 05066/90333-0
FAX No. 05066/90333-145
E Mail: [email protected]
Internet: www.helmke.de

Check List

NOTE: The check list has to be filled in before commissioning and should then be
returned to: HELMKE ORBIS GmbH, Ludwig-Erhard-Ring 7-9, 31152 Sarstedt

Requirement: The starter may only be put into operation by qualified

personnel.

Remarks:
Prior to attaching rotor cables to terminals K, L, M and before having linked
the slipring (wound rotor) motor to the power supply functional off load
tests on the rotor starter may be performed without having filled transformer
oil into the starter tank in order to facilitate handling and inspection.
If thereby the starter has proved faultless transformer oil may be filled in
before connecting up rotor cables (for further details see item 3).

Page 2 of 7
Type of device:
Oil cooled drum type rheostatic rotor starter
assigned the designation
DOA250/300A
Serial No.:
12000009016
For starting a slipring motor,
motor power
rotor voltage at standstill:
rotor current at full rated speed
and at full load torque:

250 kW
525 V
289 A

Type of driven machine:

BALL MILL

Circuit diagram of pilot drive unit:

3phase power supply voltage:
1phase control voltage:
Outline drawing:
Degree of protection:

SF 1043c-1
440 V, 60 Hz
220 V, 60 Hz
MZ 1630b, size 2
IP 54

Will the run up procedure take place under the conditions and technical data for
which the starter has been calculated and designed?
(Please confirm)

yes

(Please confirm)

yes

Have steps been taken to prevent overload?

1.

Measuring Resistance Values

Prior to applying power to the stator side of the slipring motor and before
having attached rotor cable(s) to starter terminals K,L,M test the rotor starter:
1.1

Press down the handwheel and measure the ohmic values between
terminals K and L, K and M, L and M in each starter position.
(The handwheel can be fixed in the down position by use of a clip on the end of
shaft).

Page 3 of 7

Note down the values in the table below:

Position

K-L

K-M

L-M

In initial position the ohmic values between any two of the three rotor
terminals should be approx. 0.98 Ohms ( 10%).
The minimum ohmic value should read approx. zero Ohms and be in
final working position.
If the result is not satisfactory please contact HELMKE ORBIS immediately.
2.

Functional Test of the Pilot Drive Unit

2.1

Attach the control wires to the terminal strip of the pilot drive unit.
Apply power to the pilot drive unit only.
If the handwheel still is fixed in down position, release it.

Make sure the power supply to the stator side of the slipring motor continues
to remain interrupted, also in event of switching ON the slipring motor.
2.1.1 Does the starting resistance change from max. value 10% to approx.
zero within the run up time stated on the rating plate of the starter?
(Cross out what doesnt apply)

(If not, continue at item 5)

yes/no

Page 4 of 7
2.1.2 To check the step interval monitoring system keep the handwheel
pressed down for approx. 5 seconds at the beginning of a
simulated run up procedure.
After this time has run off, monitor system must trip.
After having released the handwheel the drum controller must
automatically return to first starting position with maximum resistance in
circuit.
Has the energy cut off signal been produced?

yes/no

(Cross out what doesnt apply)

(If the answer is no then continue at item 5)

Wiper relay K3 is and remains set to approx. 0.3 seconds on
principle. (For starters with step interval monitoring system only.)
2.1.3 In case of starters having a run up control system using rotor frequency
(locked rotor control) the corresponding relay settings must also be
checked.
A frequently adopted way of control setting will cut off energy if the
drive unit doesnt gain 10 percent of full speed beginning at standstill
within 20 percent of total run up time, i.e. timer K7 would be set to 20%
of run up time and frequency relay F5 would be set to 90% of mains
frequency.
Locked rotor control:
Frequency relay F5:
Timer K7:
Timer K7 - Range::
Timer K7 Setting:

54 Hz
4s
10 s
4

Are the settings unchanged?

Scale 15

Hyst 7.5%

(Please confirm)

yes

Page 5 of 7

3.

General Testing
Functional test temperature switch
F3 /F31 85 C/120C.
F4
./. C.
Have all earthing points been properly connected?

(Please confirm)

Have all mechanical and electrical safety regulations and

other laws that are in force at site been observed?

(Please confirm)

yes

yes

Has normal, acidless mineral transformer oil having ambient

temperature been used?

(With oil being at ambient temperature the oil tank may only be filled up
to the centre of the oil sight glass.)
(Please confirm)

yes

Has the oil filling been allowed to settle for about 2 or 3 hours?

yes

Have rotor cables been connected?

yes

(Please confirm)

Handwheel unlocked?

(Please confirm)

(Please confirm)

yes

Does power supply provide either full rated voltages or else voltages within
particularly acknowledged limits for operating the starter?
(Please confirm)
yes
In case of deviations beyond 5% of the specified range make sure to first
contact HELMKE ORBIS.

Page 6 of 7
4.

Measuring Insulation Resistance

Measuring insulation resistance between the 3 rotor terminals K,L,M and the
oil tank. The result should be approx. 10 megohms.
please enter the value: .......................megohms,
(measured with 500 V or 1000 V)
Final bench tests on starters in dry state yield values of approx. 80 to 100
megohms. With long storage periods and under the effect of moisture values
can drop to below 10 megohms. A field requirement would be to achieve at
least 1000 Ohm / V; (related to rotor Volts at standstill).

5.

Readjustments
If there has been a change in operating characteristics or mistuning which
necessitates readjustment proceed as below:
Change of run up time
A change of run up time will have to comply with instructions stipulated by
HELMKE ORBIS, achieved by adjustment of step intervals with relay K2.
This must always be verified by checking the complete run up time.
After having changed run up time it will also be necessary to reset the step
interval monitor!
Tuning the step interval monitor by resetting relay K4:
General rule:
Setting of K4 = maximum step interval + 1 to 2 seconds
(where 1 or 2 seconds is the tripping time)
For easy tuning of the step interval monitor the maximum period of time
between two consecutive pulses of K3 must be measured (LED lamps are on
the relay).
Time setting on relay K2 plus a time lag caused by the speed of the pilot
motor and tripping time 1 to 2 seconds add up to the required setting of K4.
The sensitivity of control settings on K4 necessitates practical testing. On
starters where the first step interval is longer than the following intervals
tuning only refers to the first step. This is achieved by pressing down the
handwheel before starting the pilot drive unit. Time then is measured from
start to trip.

Page 7 of 7

After having completed all changes run through the complete list once
more checking each detail!!
If serious deviations are found in any section of checking procedure the starter
may only be put to work on receipt of written approval by HELMKE ORBIS.
Company: .......................................................................................................
Place, date: .....................................................................................................
Signature: ........................................................................................................

Please return this check list to:

HELMKE ORBIS GmbH
Ludwig-Erhard-Ring 7-9
31152 Sarstedt
GERMANY